Mechanical / Enclosure Designer Needed – Custom Handheld Gaming Device (3D Printed Prototype) Ended

Project Goal

The goal of this project is to create a functional, ergonomic handheld enclosure that blends:

The overall shape language and hand feel of a GBA-style device

A larger, more comfortable body to support a 5”+ screen

A modern control layout and grip ergonomics inspired by larger handhelds like the Powkiddy RGB10 Max series

The final enclosure should feel:

Comfortable during long play sessions

Balanced in the hands

Purpose-built rather than a modified off-the-shelf shell

Success = a print-ready enclosure that I can build custom electronics into.

Scope of Work
1. Enclosure CAD

Full handheld enclosure design

Split shell (front / back)

Hidden screws

Conservative, prototype-safe snap fits (optional, justified)

Designed specifically for 3D printing, not injection molding

2. Internal Layout (Mechanical only)

Mechanical placement volumes for:

5.0–5.5” display (generic envelope, not SKU-specific)

Battery

Speakers

PCB volume (RK3566 SOM + carrier assumed)

Includes:

Standoffs, ribs, bosses

Structural supports

Clearance for assembly and iteration

⚠️ No PCB routing, no electronics calculations, no EE responsibility

3. Button Mechanics

Button caps and posts

Button travel and tolerances

Suitable for tact switches or membranes

Dual analog sticks

Asymmetrical layout (Switch / Xbox style)

D-pad priority, analog sticks secondary

4. Ergonomics

Comfortable grip for extended use

No sharp edges or pressure points

Balanced hand feel

Comfort prioritised over compactness

5. Assembly Philosophy

Prioritise easy assembly and disassembly

Designed for repeated prototype iterations

Avoid fragile features that fail after multiple builds

Manufacturing Assumptions

3D printing only (SLS / MJF preferred, SLA acceptable)

No injection molding

CAD must be print-ready

Tested tolerances for SLS / MJF

Near-production geometry without mold constraints

Deliverables

Complete enclosure CAD

Internal mechanical layout

Button geometry and mechanisms

STEP file (required)

Fusion 360 file preferred

Design ready to send directly to a 3D printing service

Collaboration & Process

High involvement, frequent feedback

Iterative development

No rush – quality first

NDA required

I retain ownership of all CAD and design files

Ideal Experience

You are a good fit if you have experience with:

Consumer electronics enclosures

Handheld or ergonomic product design

3D printing–ready CAD (SLS / MJF)

Designing for assembly and iteration

Please include examples of past enclosure or product CAD work in your proposal.

Nice to Have (Not Required)

Experience designing handheld devices

Familiarity with RK3566-class products

DFM experience for non-molded prototypes

Screening Questions (please answer)

What CAD tools do you use?

Have you designed enclosures specifically for SLS or MJF printing before?

Can you share an example of a consumer electronics enclosure you’ve designed?

How do you approach ergonomic design for handheld products?

Are you comfortable delivering print-ready CAD with validated tolerances?

If this sounds aligned, I’d love to talk. read less